Design Calculation For External Pipe Rack Section PK 12 - Grid 90 To 109

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DESIGN CALCULATION FOR

EXTERNAL PIPE RACK SECTION PK 12 - GRID 90 TO 109

PROJECT
Industrial Piping & Pipe Rack

M/s. ITC Limited,


ICML, TRICHY,
ITC Limited, Central Projects Organisation
Velur village, Ilupur taluk,Viralimalai Union,
Pudukottai Dist, TamilNadu- 621 316.

DOC NO : ME / ITC / PR: PK 12

DESIGNED BY

Metec Design & Construction Engineers India Private Limited,

No: 1/460, Multi nagar Main road,


Multi Industrial Estate, Gerugambakkam,
Porur, Chennai-600 122, TamilNadu, India.
 

METEC  1 
 

PROJECT : INDUTRIAL PIPING AND PIPE RACK

LOCATION : TRICHY, TAMIL NADU

PROJECT NO : ME/ITC:1397

CLIENT : ITC LIMITED

STRUCTURE : PIPE RACK


 

REPORT VERIFICATION

DOCUMENT NO ME / ITC / PR: PK - 12 – R1

DESCRIPTION ISSUED FOR APPROVAL


REV
DATE DESCRIPTION ENGG CHECK APPVD
NO

0 23-05-2017 FIRST DRAFT MDASS VJC SA

1 12-11-2017 REVISED DRAFT MDASS VJC SA

3
 

METEC  2 
Table of Contents Page No

Chapter 1. INTRODUCTION 5

1.1 General 5

1.2 Scope 5

Chapter 2. STRUCTURE DESCRIPTION 6

2.1 General 6

Chapter 3. CODES AND STANDARDS 9

3.1 General 9

Chapter 4. LOADS AND LOAD COMBINATIONS 10

4.1.0 General 10

4.2.0 Load Calculation 10

4.2.1. Dead Load (DL) 10

4.2.2. Empty Piping Load (EPL) 10

4.2.3. Cable Tray Load (CTL) 11

4.2.4. Live Load (LL) 12

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Table of Contents Page No

4.2.5. Content Load (CL) 13

4.2.6. Friction Load ( FL) 14

4.2.7. Temperature Load (TL) 15

4.2.8. Seismic Load (SL) 15

4.2.9. Wind Load (WL) 16

4.3.0 Load Combinations 19

Chapter 5. MATERIAL PROPERTIES 20

5.1 General 20

5.2 Elastic and Physical properties 20

Chapter 6. ANALYSIS AND DESIGN 21

6.1 General 21

6.2 Design of Steel Structure 21

6.3 Member Deflections 22

Chapter 7. CONCLUSION 24

7.1 General 24

METEC  4 
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PROJECT : INDUSTRIAL PIPING AND PIPE RACK REV :1
TITLE : DESIGN BASIS REPORT DATE : 12-11-2017
 

Chapter 1. INTRODUCTION
1.1 General

This document presents the design for proposed INDUSTRIAL PIPE RACK
STRUCTURE SECTION PK 12 GRID 90 TO 109 FOR ITC LIMITED AT TRICHY as
per the relevant codes and standards. The steel structure comprises of pipe rack modules to
support the pipes and cable trays running along, including walkway platforms aside.

The steel structure is designed and analyzed using Limit State Design philosophy
as per IS 800:2007 section 12 and relevant IS codes mentioned in chapter 3. STAAD Pro
design and analysis software is used for the analysis and design of the pipe rack.

1.2 Scope

This Design Report (DR) describes the methodology for structural analysis and
design of INDUSTRIAL PIPE RACK STRUCTURE SECTION PK 12 GRID 90 TO 109
FOR ITC LIMITED AT TRICHY, to satisfy functional requirements and ensure structural
integrity of the structure as envisaged in the applicable safety standards.

The scope of this DR is to describe the loads and load combinations, material
properties and methodology used for analysis and design of structural steel members.
Strength assessment of concrete structures and foundation is outside the scope of this DR.
 

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Chapter 2. STRUCTURE DESCRIPTION


2.1 General

This chapter describes the basic structural layout of proposed INDUSTRIAL

PIPE RACK STRUCTURE SECTION PK 12 GRID 90 TO 109 FOR ITC LIMITED


AT TRICHY as per the client requirements and standards. Basic structural layouts are
shown in
fig 2.1 to 2.4. Basic structural geometry is as follows:

 Pipe Rack Span = 16.00 M & 4M+4M 



 Width = 1.50 M (Clear W – 1.40m) 

 Height – Tier –II = 0.600 M (Clear Ht – 0.50m) 

 Height – Tier –III = 0.500 M (Clear Ht – 0.40m) 

 Column Height = 5.550 M (Pedestal Top – 89.800 To Bottom Tier – 95.35) – Fgl
88.800 
 Column Height = 3 M (Pedestal Top – 89.800 To Bottom Tier – 92.90) – Fgl 88.800 

Fig 2.1 Structure section for PK 12 GRID 90 TO 109


 

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Fig 2.2 Full structure geometry Grid 90 to 93
 

Fig 2.3 Full structure 3-D view Grid 90 to 92

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Fig 2.2a Full structure geometry Grid 93to 109

   
Fig 2.4A Structure section geometry for Fig 2.4B Structure section geometry for
PK 12 GRID 90 TO 92 PK 12 GRID 93TO 109

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Chapter 3. CODES AND STANDARDS


3.1 General

This chapter lists out the applicable codes and standards for the analysis, design
and detailing of proposed INDUSTRIAL PIPE RACK STRUCTURE SECTION PK 12
GRID 90 TO 109 FOR ITC LIMITED AT TRICHY.

1. IS 800: 2007, General Construction in Steel – Code of Practice

2. IS 875 (part 1) –1987, Code of practice for design loads (other than earthquake) for

buildings & structures – Dead loads

3. IS 875 (part 2) –1987, Code of practice for design loads (other than earthquake) for

buildings & structures – Imposed loads

4. IS 875 (part 3) –1987, Code of practice for design loads (other than earthquake) for

buildings & structures – Wind loads

5. IS: 1893(Part-1) – 2002, Criteria for earthquake resistant design of structures:

General provisions and buildings.

6. IS 2062: 2011 – Steel for general structural purposes, Bureau of Indian Standards (BIS)

7. IS 808: 1989 – Dimensions for hot rolled steel beam, column, channel and angle sections.
 

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Chapter 4. LOADS AND LOAD COMBINATIONS


4.1 General

This chapter describes the various loads considered for the design of proposed

INDUSTRIAL PIPE RACK STRUCTURE SECTION PK 12 GRID 90 TO 109 FOR


ITC LIMITED AT TRICHY.

4.2 Load Calculation

The design loads shall be calculated as described in the following sections.

4.2.1. Dead Load (DL)

Dead load consists of self-weight of various structural elements indicated below.

Table 4.1 Dead Loads

SL NO ITEMS WEIGHT

1.10 (considered including the


1 Self-weight of the structure
weight of connections)

2 Walk way Chequered plate & Rail 0.75 kN/m2

Load calculation in STAAD

Walkway width = 0.8 m

Clear Bay space = 2.0 m

Weight = 0.75 KN/m2 = 0.75*2.0 = 1.5 KN/m

4.2.2. Empty Piping Load (EPL)

Empty Piping loads are the material weight of the pipes without any content.
These loads will be added with the dead load of the structure in the structural design. Empty
Piping loads are listed in table 4.2.

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Table 4.2 Empty Pipe Loads

Outside Dia Thickness Internal


S.No Tier Size Inch(mm) EPL (Kg/m)
(mm) (mm) Dia (mm)
10(250)-HYD 273 5.9 261.2 38.90
8(200)-SPK 219.1 5.9 207.3 31.00
TIER-I
1 8(200)-CHWS 219.1 5.9 207.3 34.00
8(200)-CHWR 219.1 5.9 207.3 34.00
TIER-1- TOTAL LOAD 137.90
1(25) - RO 33.3 4 25.3 2.93
3 (80) CA 88.9 4.8 79.3 9.90
2(50) FO 60.3 4.5 51.3 6.19
2(50) HSD 60.3 4.5 51.3 6.19
TIER-II
2 3 (80) WL 88.9 4.8 79.3 9.90
1-1/2 (40) WL 48.3 4 40.3 4.37
1-1/4 (32) WL 42.2 4 34.2 3.79
1-1/2 (40) LPG 48.3 3.2 41.9 3.60
TIER - II- TOTAL LOAD 46.87

Load calculation in STAAD

Rack width = 1.5 m

Clear Bay space = 2.0 m

Tier I

Weight of material = 137.9 kg/m

Udl applied = 137.9*2.0/1.5 = 1.84KN/m

Tier II

Weight of material = 46.87 kg/m

Udl applied = 46.87*2.0/1.5 = 0.63 KN/m

4.2.3. Cable Tray Load (CTL)

Cable Tray loads are the material weight of the trays carrying cables. Weight of
cables is also added to the dead weight of trays which is added up to the Cable tray load.
These loads will be added with the dead load of the structure in the structural design.

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Table 4.3 Cable Tray Loads

Dead weight of cable tray 18


Pipe Weight Chart Section - PD 005 - GRID 40 TO 48
Total weight - Tier – II in kg/m 80

Dead weight of cable tray 18


Pipe Weight Chart Section - PD 005 - GRID 40 TO 48
Total weight - Tier – III in kg/m 80

Load calculation in STAAD

Rack width = 1.5 m

Clear Bay space = 2.0 m

Tier III & IV

Cable tray dead load assumed= 18 kg/m = 0.18*2=0.36 KN/m

Udl = (0.36*2)/1.5 = 0.5 KN/m

Weight of LT and ELV cables = 80kg/m

Udl =80*2.0/1.5 = 1.1 KN/m

Total Udl applied = 1.1+0.5=1.6 KN/m

4.2.4. Live Load (LL)

Live loads are those gravity loads produced by the use and occupancy
of the structure. These include the weight of all movable loads; such as personnel,
tools, miscellaneous equipment, movable partitions, parts of dismantled
equipment, stored material, etc.

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Table 4.4 Live load

Case Load

Walk way 0.75 kN/m2.

Load calculation in STAAD

Walkway width = 0.8 m

Clear Bay space =2.0 m

Weight = 0.75 kN/m2 = 0.75*2.0= 1.5 kN/m

4.2.5. Content Load (CL)

Content loads are the weight of the weight of contents in operating


condition. These loads will be added with the live load of the structure in the
structural design.

Table 4.5 Content Loads


Internal
Outside Thickness
S.No Tier Size Inch(mm) Dia CL (Kg/m)
Dia (mm) (mm)
(mm)
10(250)-HYD 273 5.9 261.2 53.56
8(200)-SPK 219.1 5.9 207.3 33.73
TIER-I
1 8(200)-CHWS 219.1 5.9 207.3 33.73
8(200)-CHWR 219.1 5.9 207.3 33.73
TIER- I - TOTAL LOAD 154.76
1(25) - RO 33.3 4 25.3 0.50
3 (80) CA 88.9 4.8 79.3 0.01
2(50) FO 60.3 4.5 51.3 1.91
2(50) HSD 60.3 4.5 51.3 1.65
TIER-I
2 3 (80) WL 88.9 4.8 79.3 4.94
1-1/2 (40) WL 48.3 4 40.3 1.27
1-1/4 (32) WL 42.2 4 34.2 0.92
1-1/2 (40) LPG 48.3 4 40.3 0.003
TIER - II - TOTAL LOAD 11.20

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Load calculation in STAAD

Rack width = 1.5 m

Clear Bay space = 2.0 m


Tier I

Content load = 154.76 kg/m

Udl applied = 154.76*2/1.5 = 2.06 KN/m

Tier II

Content load = 11.20 kg/m

Udl applied = 11.20*2/1.5 = 0.15 KN/m

4.2.6. Friction Load ( FL)

Friction loads are applied as 30 % of operating piping load. Friction loads are
applied in both longitudinal and transverse direction. Friction loads are resolved applied
along the grid 36-37.

Load calculation in STAAD

Rack width = 1.5 m

Clear Bay space = 2.0 m


Tier I

Friction load = 30% of pipe operating load

= 0.3* {[(137.9+154.76)x2.0]/1.5}

= 0.3*3.91≈ 1.17 KN/m


Tier II

Friction load = 30% of pipe operating load

= 0.3* {[(46.87+11.20)x2.0]/1.5}

= 0.3*0.774≈ 0.23 KN/m

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4.2.7. Temperature Load (TL)

All support structures and elements thereof shall be designed to accommodate


the loads or effects produced by thermal expansion and contraction of structure. For design
of platforms thermal loads calculated on basis of operating temperature shall be combined
with seismic loads. Temperature loads shall be included with operating loads in the
appropriate load combinations. Temperature load shall have the same load factor as dead
load. Temperature loads and displacements shall be calculated on the basis of the difference
between ambient or equipment design temperature and installed temperature.

Temperature gradient considered for the design = 15 0C


Expansion joints are also added in the structure which is marked in the drawings.

4.2.8. Seismic Load (SL)


The loads due to Earthquake are generated by the response of the structure to
design spectrum as specified in IS 1893 (Part 1). The masses considered in the structure,
generating the earthquake loads are due to dead weight of permanent construction, 50% live
loading on the platforms. Joint weights are calculated and applied accordingly. Seismic
loads are applied in both directions.

Table 4.6 Earth Quake load

Zone II

Zone Factor 0.10

Reduction Factor 4

Damping 2%

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4.2.9. Wind Load (WL)

The loads due to wind are calculated as per the provisions specified in IS 875
(Part 3).Wind load parameters are given in table 4.7 and table 4.8.

Table 4.7 Wind load parameters

Parameters

Regional basic wind speed 47 m/s

Terrain Category 2

Class of structure A

Risk Coefficient , K1 1.07

Terrain, Height and Structure size factor , K2 1

Topography factor, K3 1

Design life of the building 100 years

Percentage of openings in the building Open Structure

The design wind speed and pressure is tabulated in Table 4.5.Wind pressure is
calculated as:Pz= 0.6 Vz2

Table 4.8 Wind pressure

Height (m) Vb (m/s) K1 K2 K3 Vz (m/s) Pz (kN/m2)

7 47 1.07 1 1 50.3 1.52

The force coefficients considered for open structure as per IS 875 part 3.

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Table 4.9 Force coefficients, Cf from IS 875 part 3

Full structure (table 28) 1.9

Flat sided members (table 26) 2.0

Circular cross sections (table 23) 0.7

Load calculation in STAAD

Rack width = 1.5 m

Clear Bay space = 2.0 m

TIER I

Wind load on pipes

Wind load = Projected Area * Cf * Pd (section 6.3 IS 875 part 3)

Projected Area = Bay space * (Dia)

= 2*0.0254*10

0.508 = 0.51 m2

Cf = 0.7 (table 23)

Wind speed at Trichi = 47 m/s

Vz=1.07*1*1*47 = 50.3 m/s (Category 2, class A)

Pd = 0.6*50.3*50.3 = 1.52 KN/m2

WL = 0.51 * 0.7 * 1.52

= 0.547/1.5 = 0.362 KN/m

TIER I

Wind load on pipes

Wind load = Projected Area * Cf * Pd (section 6.3 IS 875 part 3)

Projected Area = Bay space * (Dia)

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= 2*0.0254*3

0.152 = 0.16 m2

Cf = 0.7 (table 23)

Wind speed at Trichi = 47 m/s

Vz=1.07*1*1*47 = 50.3 m/s (Category 2, class A)

Pd = 0.6*50.3*50.3 = 1.52 KN/m2

WL = 0.16 * 0.7 * 1.52

= 0.17/1.5 = 0.12 KN/m

TIER II & III

Wind load on cable trays

wind load = Projected Area * Cf * Pd

Projected Area= Bay space * Depth of tray (assumed as 150mm)

= 2*0.15

= 0.3 m2

Cf = 2 (table 26)

WL = 0.3 * 2 * 1.52

= 0.912/1.5 = 0.61 KN/m

Wind load on hand rail

Wind load = Projected Area * Cf * Pd (section 6.3 is 875 part 3)

Projected Area= 0.15 m2

Cf = 0.7 (table 23)

WL = 0.15 * 0.7 * 1.52

= 0.16/2 = 0.08 KN/m

METEC  18 
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4.3 Load Combinations

Structure has to be designed for both strength and serviceability criteria. For the
strength design, load combinations as specified in IS 800: 2007 shall be used. For
ascertaining safety under service load conditions the un-factored load combinations as
specified in IS 800: 2007 shall be used. These combinations are primarily framed to cater
for serviceability condition requirements such as member local deflections and overall
structural deflection checks. Various load combinations as per the partial safety factors given
in IS 800: 2007 are listed below for strength and serviceability criteria.

LOAD COMBINATIONS

STRENGTH DESIGN SERVICEABILITY DESIGN

1. 1.5 (DL + EPL + CTL) + 1.5(LL + CL) 1. 1.0 (DL + EPL + CTL) + 1.0 (LL + CL) + 1.0 TL

2. 1.2 (DL + EPL + CTL) + 1.2 ( LL + CL) +1.2 SL 2. 1.0 (DL + EPL + CTL) + 0.8 ( LL + CL) + 0.8 SL+ 1.0 TL

3. 1.2 (DL + EPL + CTL) + 1.2 ( LL + CL) +1.2 WL 3. 1.0 (DL + EPL + CTL) + 1.0 SL + 1.0 TL

4. 1.5 (DL + EPL + CTL) + 1.5 SL 4. 1.0 (DL + EPL + CTL) + 0.8 ( LL + CL) +0.8 WL

5. 1.5 (DL + EPL + CTL) + 1.5 WL 5 1.0 (DL + EPL + CTL) + 1.0 WL

6. 0.9 (DL + EPL + CTL) + 1.5 SL

7. 0.9 (DL + EPL + CTL) + 1.5 WL

8. 1.5 (DL + EPL + CTL) + 1.5(FL) + 1.5 (TL)

9. 1.2 (DL + EPL + CTL) + 1.2 ( LL + CL) + 1.2(FL) + 1.2 (TL)

10. 1.2 (DL + EPL + CTL) + 0.5 ( LL + CL) +2.5 SL

11. 0.9 (DL + EPL + CTL) + 2.5 SL

1. Abbreviations; DL=Dead load, LL=Live load, EPL =Empty Pipe load, CTL=Cable Tray
load, CL= Content Load, SL= Seismic load, FL = Friction Load, TL= Temperature load,
WL = Wind load
 
 

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Chapter 5. MATERIAL PROPERTIES

5.1 General

This chapter describes the physical and elastic properties for various materials
used in the construction of proposed INDUSTRIAL PIPE RACK STRUCTURE SECTION
PK 12 GRID 90 TO 109 FOR ITC LIMITED AT TRICHY. These are used for
defining the stiffness calculation of the modelled structural members in static and
dynamic analyses.

5.2 Elastic and Physical properties

The elastic properties are tabulated below.

Table-5.1 Elastic Properties of Materials

SL. Elastic Modulus Poisson’s Unit weight


Material Member description
No. Ratio
(kN/m2) (kN/m3)
Structural
1 steel YST 250 Beams and Bracings. 2 x 108 based on 0.3 78.5
Grade IS:800-2007
Structural
2 steel YST 310 Columns 2 x 108 based on 0.3 78.5
Grade IS:800-2007
Structural
3 steel YST 250 End plates, Stiffeners, 2 x 108 based on 0.3 78.5
Grade IS:800-2007

Unit Weights of major structural materials are only provided here. Unit weights of
all other materials can be obtained from IS 875 (part I).

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Chapter 6. ANALYSIS AND DESIGN

6.1 General

This Chapter presents details of the design of strengthened steel beams of proposed
INDUSTRIAL PIPE RACK STRUCTURE SECTION PK 12 GRID 90 TO 109 FOR ITC
LIMITED AT TRICHY. Limit state design philosophy is used to carry out the design for
the steel structure as per IS 800: 2007 using STAAD.Pro software.

6.2 Design of Steel Structure

The behaviour of the structure under various load combinations are analysed
using STAAD Pro. These analysis results are used to obtain the most critical load
combinations for each member and the same is used to design the members.

All horizontal members primarily transfer the loads by bending and are
designed as flexural members. The utilization ratios of typical frame elements are given in
Table 7.1.

Table 6.1 Utilization Ratios.

MEMBER MEMBER UTILISATION ALLOWABLE LOAD


MEMBER CLAUSE REMARKS
PROPERTY NUMBER RATIO RATIO CASE
RHS
COLUMN 250X250X8 601 0.590 1.0 SEC 9.3.1.3 112 SAFE

BEAM ISMB 200 790 0.573 1.0 SEC 9.3.2.2 111 SAFE
ISA
BRACINGS 812 0.847 1.0 SEC 9.3.2.2 101 SAFE
90X90X8

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6.3 Member Deflections.


The maximum deflection for flexural elements is checked in accordance with
relevant codes mentioned in chapter 3. The allowable deflection limits for various members
considered are given in Table 6.1

Table 6.2-Allowable Deflections

Member Direction Deflection Limit

Beams
Vertical Span/300
(Simple span)

Cantilever Vertical Span/150

Columns Horizontal Height/200

Table 6.3- Actual Deflections from Staad

Actual Allowable
Member Direction Remarks
Deflection(mm) deflection(mm)

Beams
Vertical 26.617 64.00 SAFE
(Simple span)

Cantilever Vertical 0.609 5.30 SAFE

Columns Horizontal 27.101 36.25 SAFE

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Fig 6.1 Node numbers of supports

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Chapter 7. CONCLUSION

7.1 General

This DR gives a brief description of the structural layout and design


Considerations for strengthening of the proposed INDUSTRIAL PIPE RACK STRUCTURE
SECTION PK 12 GRID 90 TO 109 FOR ITC LIMITED AT TRICHY. The DR also
explains the loads and load cases considered in the analysis and design of the structure. The
DR further explains the various aspects of static and dynamic analysis being performed for
the structure and design procedures being adapted for the design of steel members.

It is also certified that the INDUSTRIAL PIPE RACK STRUCTURE


SECTION PK 12 GRID 90 TO 109 FOR ITC LIMITED AT TRICHY is structurally
adequate and safe and satisfy the requirements of Bureau of Indian Standards codes. All
deflection values are coming within permissible limits and design strength of each
member is adequate for the force on the members. It satisfies both strength and
serviceability criteria as per the stipulations of the Bureau of Indian Standards.

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